GUJARAT TECHNOLOGICAL UNIVERSITY
Chandkheda, Ahmedabad
HASMUKH GOSWAMI COLLEGE OF ENGINEERING
Vehelal, Ahmedabad (Affiliated with GTU)
A Summer Internship Report on
“MANUFACTURING OF INDUSTRIAL CONTROL PANEL”
At the Company
“VARNIRAJ AUTOMATION”
Under the subject
Summer Internship (3170001)
Electrical Engineering Department
Submitted By
Dave Aman Shailesh bhai.
210240109505
Academic Year
August - 2023
TEAM ID : 343014
HASMUKH GOSWAMI COLLEGE OF ENGINEERING
Vehelal, Ahmedabad (Affiliated with GTU)
COMPLETION CERTIFICATE
This is to certify that the Summer Internship at “VARNIRAJ
AUTOMAION” has been satisfactorily completed by Dave Aman Shailesh
bhai (210240109505) under my guidance in the partial fulfilment of the
Degree of Bachelor of Engineering in Electrical Engineering (7th Semester)
of the course Summer Internship (3170001) work during the academic year
2023-2024.
Internal Guide Head of Department
Prof. Chirag Patel Dr. Maulik Raichura
Gujarat Technological University ii HGCE
TEAM ID : 343014
GTU Internship Completion Certificate (Download from
PMMS Portal, Take a Colour Print , Get it Signed by your
Internal Guide and attach here)
Gujarat Technological University iii HGCE
TEAM ID : 343014
Gujarat Technological University iv HGCE
TEAM ID : 343014
STUDENT’S DECLARATION
I undersigned Dave Aman Shailesh Bhai student of HGCE B.E
Electrical Engineering 7th Semester, declare that summer internship project
titled “MANUFACTURING OF INDUSTRIAL CONTROL PANEL” is a
result of my/our own work and my/our indebtedness to other work
publications, references, if any, have been duly acknowledged. If I/we are
found guilty of copying any other report or published information and showing
as my/our original work, I understand that I/we shall be liable and punishable
by Institute or University, which may include ‘Fail’ in examination, ‘Repeat
study & re-submission of the report’ or any other punishment that Institute or
University may decide.
Name of Student Signature
Dave Aman S.
Gujarat Technological University v HGCE
TEAM ID : 343014
ACKNOWLEDGEMENT
I wish to express our sincere gratitude to our External guide Mr. Ankit
Patel for continuously guiding me at the company and answering all my
doubts with patience. I would also like to thank my Internal Guide Prof.
Chirag Patel, Head of EE Department, Dr. Maulik Raichura for helping us
through our summer internship by giving us the necessary suggestions and
advice along with their valuable co-ordination in completing this summer
internship.
I also thank our parents, friends and all the members of the family for
their precious support and encouragement which they had provided in
completion of our work. In addition to that, I would also like to mention the
company personals who gave us the permission to use and experience the
valuable resources required for the internship.
Thus, In conclusion to the above said, I once again thank the staff
members of VARNIRAJ AUTOMATION for their valuable support in
completion of the summer internship.
Thank You
Dave Aman S.
Gujarat Technological University vi HGCE
TEAM ID : 343014
ABSTRACT
This was my first experience being in part of any industrial offline
Internship. During initial days we were taught some basic topics about the
control panel that can be useful in near future in our internship. The main goal
of this Internship was to learn the basic designing and making of the control
panel. Which is the most using right now through world -wide. We learn this
topics as soon as we deed. We taught about lots of things like use of circuit
breaker, PLC, SCADA, Contactors and etc.. It was a great experience to be a
part of this internship as I got an opportunity to learn some good things.
Gujarat Technological University vii HGCE
TEAM ID : 343014
Table of Contents
COMPLETION CERTIFICATE………………………………………………..ii
GTU INTERNSHIP COMPLETION CERTIFICATE…………………….….iii
COMPANY CERTIFICATE…………………………………………………....iv
STUDENT’S DECLARATION…………………………………………………..v
ACKNOWLEDGEMENT……………………………………………………….vi
ABSTRACT……………………… ……………………………………………..vii
LIST OF FIGURES ............................................................................................... 3
LIST OF ABBREVIATION.................................................................................4
CHAPTER 1 : INTRODUCTION.................................................................... 5
1.1 ESTABLISHMENT OF THE COMPANY : .............................. 5
1.2 INTRODUCTION TO COMPANY : ......................................... 6
1.3 MAIN ASPECTS OF THE COMPANY : ...................................6
CHAPTER 2 : PANEL AUTOMATION............................................................... 7
2.1 INTRODUCTION TO TOPIC :...................................................7
2.2 TYPES OF PANEL AND THEIR FUNCTION : .......................7
2.2.1 POWER CONTROL PANEL : .......................................8
2.2.2 MOTOR CONTROL PANEL : .......................................9
2.2.3 AUTOMATION CONTROL PANEL : ........................10
CHAPTER 3 : COMPONENT USED IN PANEL .............................................11
3.1 INNER BODY PARTS : .............................................................11
3.1.1 COMPONENTS : ...........................................................11
3.2 OUTER BODY PARTS : ............................................................16
3.2.1 COMPONENTS :...........................................................16
CHAPTER 4: DEPARTMENT INFORMATION .............................................20
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4.1 BODY MAKING DEPARTMENT :..........................................20
4.2 ASSEMBLING DEPARTMENT : .............................................21
CHAPTER 5 : ADVANTAGES AND DISADVANTAGES ..............................22
5.1 ADVANTAGES OF PANEL AUTOMATION: .......................22
5.2 DISADVANTAGES OF PANEL AUTOMATION: .................22
CHAPTER 6 :
CONCLUSION.............................................................................23
CHAPTER 7: REFERENCE ...............................................................................24
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List of Figures
Figure 1 : Location Image of Varniraj Automation ........................... 5
Figure 2 : Automation And Control Panels......................................... 6
Figure 3 : Power Control Panel ............................................................ 8
Figure 4 : Motor Control Panel ............................................................ 9
Figure 5 : Automation Control Panel................................................. 10
Figure 6 : Main Circuit Breaker ........................................................ 11
Figure 7 : Transformer ....................................................................... 12
Figure 8 : Terminal Blocks ................................................................. 13
Figure 9 : Relays and Contractors .................................................... 14
Figure 10 : Networks Switches ........................................................... 14
Figure 11 : Programmable Logic Controller (PLC) ......................... 15
Figure 12 : Indication Lamp .............................................................. 16
Figure 13 : Measuring Instrument (Voltmeter) ................................ 17
Figure 14 : Cooling Fan ...................................................................... 18
Figure 15 : Human Machine Interface (HMI) .................................. 19
Figure 16 : Body Making Department .............................................. 20
Figure 17 : Assembling department ................................................... 21
List Of Abbreviation
PLC Programmable logic controller
SCADA supervisory control and data acquisition
CP control panel
PC personal computer
EP ethernet pot
R red light
Y yellow light
B green light
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CHAPTER 1 : INTRODUCTION
Since 2002, the Varniraj Automation being to have their company to shine in market and from
that till now they have good reputation in the market and have their aim to balance the supply and
demand of their customer (like industries, small units.)
1.1 Establishment Of The Company :
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Figure 1 : Location Image of Varniraj Automation
The company establish their pillars in the market in 2002 first in the Ahmedabad ,Gujarat
by Mr. Ankit Patel (owner of the company). This company have very good reputation in the market
since then. Their aim or objectives are to make control panel which is very important part now
days in advance economy .There products were also sold to government too .
Our company has trying to establish their pillar in the international market also but it is not
fully implemented in a process stage and trying to sell there product to overseas company.
1.2 Introduction To Company :
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Our company making an products which can control the machine, home appliances,
small/big motors by making control panel , power panel , automation panel. All this panel used
to control the electric current, voltage etc.
According to there name they have different functions which will be applicable to the
different machines and different industries as per their requirement.
Our company include some designated people like owner of the company, managing
director of the company and some 20+ workers are working in the company .
Figure 2 : Automation And Control Panels
1.3 Main Aspects Of The Company :
Main aspect is to make a control panel as per the requirement of the customer
(industry/small units). This company is here to fulfil the required demand of the market and
to make a sufficient profit .
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CHAPTER 2 : PANEL AUTOMATION
2.1 Introduction To Topic :
An electrical control panel is an enclosure, typically a metal box or plastic molding which
contains important electrical components that control and monitor a number of mechanical
processes. They are 14nergized systems that require maintenance, with planned preventative
maintenance and condition-based monitoring being the most effective methods. Electrical
personnel will need to gain access within control panels for fault finding, adjustments, and
electrical safety testing. Operators will interact with the controls of the panel to operate and control
the plant and process. Components within the control panel will facilitate many tasks, for example,
they may monitor pressure or flow within a pipe and signal to open or close a valve. They are
commonplace and integral to most industries. Problems with them, including neglect, can cause
havoc to any business operation and endanger employees. This makes the safe operation of panels
a desirable skill for both electrical and non-electrical workers.
Control panels come in many shapes and sizes. They range from a small box on a wall
through to long rows of cabinets located in dedicated plant areas. Some controls are located in a
control room, under the supervision of a small team of production co-coordinators whilst others
are placed close to machinery and are under the control of certain production operatives. Another
form of control panel, common in the UK, is the Motor Control Centre or MCC, which includes
all of the motor starting and control equipment to drive heavy plant, and which may, in certain
circumstances include high voltage supplies such as 3.3 kV and 11 kV.
2.2 Types Of Panel And Their Function :
The function of panel is to control the machine or electric appliances and other electric
components through control panel. It can control all those devices which need electric current.
There are 3 types of control panel are :
➢ Power Control Panel
➢ Motor Control Panel
➢ Automation Control Panel
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2.2.1 Power Control Panel :
An electrical control panel is an enclosure, typically a metal box or plastic molding which
contains important electrical components that control and monitor a number of mechanical processes.
They are 15nergized systems that require maintenance, with planned preventative maintenance and
condition-based monitoring being the most effective methods. Electrical personnel will need to gain
access within control panels for fault finding, adjustments, and electrical safety testing. Operators will
interact with the controls of the panel to operate and control the plant and process. Components within
the control panel will facilitate many tasks, for example, they may monitor pressure or flow within a
pipe and signal to open or close a valve. They are commonplace and integral to most industries.
Problems with them, including neglect, can cause havoc to any business operation and endanger
employees. This makes the safe operation of panels a desirable skill for both electrical and nonelectrical
workers.
Figure 3 : Power Control Panel
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2.2.2 Motor Control Panel :
A motor control centre (MCC) is an assembly to control some or all electric panel in a
central location. It consists of multiple enclosed sections having a common power bus and with
each section containing a combination starter, which in turn consists of motor starter, fuses or
circuit breaker, and power disconnect. A motor control centre can also include push buttons,
indicator lights, variable frequency drivers, programmable logic control, and metering equipment.
It may be combined with the electrical service entrance for the building.
Figure 4 : Motor Control Panel
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Uses:
Electrical motor control panels are designed house motor controls, drives, relays, switches
and transformers to operate motor equipment. They can be used in both low and medium voltage
applications and can be customized for a wide range of motor controls and starters.
2.2.3 Automation Control Panel :
Automation control panels are one of the most important pieces of equipment for any
industrial facility. We all know that machines and equipment across the industrial, manufacturing,
and commercial sectors are getting automated. At the same time, such automation must be
monitored. That is where automation control panels come into the picture.
Figure 5 : Automation Control Panel
Uses:
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They are used to monitor and control heavy-duty and large-scale machinery in industrial
and commercial applications. Automation control panels can perform both simple and complex
processes by employing relays, timers, sensors, starters, and controllers.
CHAPTER 3 : COMPONENT USED IN PANEL
First of all we study about two Parts of the panel they are :
➢ Inner body parts.
➢ Outer body parts.
3.1 Inner body parts :
Inner part of the panel includes some important parts like main circuit breaker, transformer,
terminal blocks, programmable logic controller, relays and contactors, network switches,etc.
3.1.1 Components :
➢ Main Circuit Breaker :
This is like the disconnect of the main electrical panel leading into a home or office. The
main circuit breaker is where the power comes into the control panel for all of the devices. This
circuit breaker generally has a disconnect on the outside of the panel that allows us to shut off the
power. Always remember the topside of the circuit breaker will still have power. The power that
comes into the panel can be anywhere from 480 volts to as low as 120 volts.
Figure 6 : Main Circuit Breaker
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➢
Transformer :
The purpose of the transformer is to transfer electric power from the primary circuit
to the secondary circuit. The transformer either reduces (steps down) or increases (steps
up) the voltage to match the requirements of the control circuit. Magnetic field from
primary winding induces voltage in the secondary winding. Depending on the incoming
voltage, transformers may reduce voltage to 120V for various components or step down
voltage to 24V in instances where incoming power is 120V.
Figure 7 : Transformer
Therefore, the transformer used in between main power supply and miniature
circuit breaker (MCB).
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Terminal Blo cks:
A terminal block consists of two terminals that can join two or more wires
together. Terminal blocks can be arranged with several other blocks in a strip mounted on
a DIN rail to run power from one source to several devices throughout the panel.
In control systems, terminal blocks are used to connect panel -mounted equipment
to power and field wiring. A typical automation system inside of an equipment rack may
contain any number of components (such as controllers, PLCs, I/O modules, etc.)
mounted on DIN rails and connected to the outer parts.
Figure 8 : Terminal Blocks
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Relays And Contactors :
A contactor joins 2 poles together, without a common circuit between them, while
a relay has a common contact that connects to a neutral position. Additionally, contactor s
are commonly rated for up to 1000V, while relays are usually rated to only 250V.The
PLC outputs will be wired to a bank of relays that will close an internal contact that will
send power out to turn ON or OFF a device on the assembly line.
Figure 9 : Relays and Contractors
➢ NetworRk s Switches:
k We will also have a network switch located somewhere near the PLC. This will
be powered with 24 volts and it will be the HUB for our communication to and from the
PLC to network compatible devices on the assembly line.
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Figure 10 : Networks Switches
TEAM ID : 343014
➢ Programmable Logic Controller (PLC) :
Programmable Logic Controllers (PLCs) are small industrial computers with
modular components designed to automate customized control processes. PLCs are often
used in factories and industrial plants to control motors, pumps, lights, fans, circuit breakers
and other machinery. Integrated PLC Panel can monitor any process and provide data
wherever and however you need it.
The PLC is like the brain of the entire process. The PLC will have a CPU where the
logic program is stored.
It will have associated inputs and outputs which will help control and monitor the
Assembly line.
There are many components to a PLC, but most of them can be put in the following
three categories:
• Processor (CPU)
• Inputs
• Outputs
Figure 11 : Programmable Logic Controller (PLC)
3.2 Outer body parts :
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Outer part of panel includes some components are indication lamp, measuring instrument
(voltmeter), cooling fan, human machine interface, selective switches, etc.
3.2.1 Components :
➢ Indication Lamp :
Indicator lamp is usually used to reflect the working state of the circuit (electric or
non-electric), the working state of the electrical equipment (operation, shutdown or test)
and the position state (closed or disconnected), etc. An indicator lamp used commonly
colours are red, green, yellow, blue, white. Yellow means standby, green means normal
operation, red means emergency stop.
Figure 12 : Indication Lamp
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Measuring Instrument (Voltmeter) :
Voltmeter, is a instrument that measures voltages of either direct or alternating
electric current on a scale usually graduated in volts, millivolts (0.001 volt), or kilovolts
(1,000 volts). Many voltmeters are digital, giving readings as numerical displays.
Voltmeter is device which is used to check input and output voltages of various
equipment such as motors, batteries, medical equipment, electrical panel boards , plastic
machinery and electronic devices etc.
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Figure 13 : Measuring Instrument (Voltmeter )
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➢
Cooling Fan :
Fans are widely used for many reasons, both individually and in clusters, to provide
forced-air convection cooling. They are easy to use, provide vital airflow, and can be
installed in a variety of chassis and systems locations. Their operating principle is basic
physics: moving air is effective in cooling objects by absorbing heat from the object and
then transferring that heat elsewhere to be dissipated. The amount of energy transferred is
dependent upon the mass of the moving air, the specific heat of the moving air, and the
temperature change imparted to the moving air.
Figure 14 : Cooling Fan
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Human Machine Interface (HMI) :
A Human-Machine Interface (HMI) is a user interface or dashboard that connects a
person to a machine, system, or device. While the term can technically be applied to any
screen that allows a user to interact with a device, HMI is most commonly used in the
context of an industrial process. One of those devices is our “Human Machine
Interface” or HMI. An HMI can be mounted locally onto a panel door or in a remote panel
located closer to the machinery. The HMI can be a very dynamic tool in assisting the
operator in controlling and monitoring the machinery. The PLC will pass signals over the
network to the HMI for monitoring and the HMI can send signals to the PLC for controlling
the machinery.
Figure 15 : Human Machine Interface (HMI)
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➢
CHAPTER 4: DEPARTMENT INFORMATION
There Are Two Types of Department are :
➢ Body Making Department
➢ Assembling department
4.1 Body Making Department :
In this department the panel of the body is made which is very important part of the panel
and body made of metal: Aluminium. The back panel is a sheet of metal that is mounted on the
inside of the enclosure that allows us to drill mounting holes for different devices which leads us
to our next component, DIN rails.
A DIN rail is a metal rail with a standard width used for mounting electrical devices inside.
The next component inside the electrical control panel is wiring Duct. Ducts allow us to route the
wires in an organized and efficient way while also reducing electrical noise between devices.
Figure 16 : Body Making Department
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4.2 Assembling Department :
Here all the part were get assemble to make the working panel and connection are also done
by them. Control panel manufacturing is traditionally a labor-intensive process with few options
for automation. Most operations are done manually, including engineering and lay out; punching
and drilling the back panels and enclosures; cutting, stripping, crimping and labelling the wires;
installing the components; and wiring the panels. Existing engineering documents are often
manually modified for new projects, resulting in long quoting cycles. Often, revisions occur during
production, and all documentation, such as drawings, schematics, bills of material, 2D and 3D
layouts, and various lists and instructions, must be manually revised at once.
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Figure 17 : Assembling department
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CHAPTER 5 : ADVANTAGES AND DISADVANTAGES
5.1 Advantages of Panel Automation:
• Lower operating costs.
• Improved worker safety.
• Reduced factory lead times.
• A faster return on investment.
• Ability to be more competitive.
• Increased production output.
• Consistent and improved part production and quality.
• A smaller environmental footprint.
5.2 Disadvantages of Panel Automation:
• Fixed circuit operation.
• PLCs manufacturers offer only closed loop architecture.
• PLCs are propitiatory, which means software and parts one manufacturer can’t be easily
used in combination with part of another manufacturer.
• Number of optional modules must be added to maximize flexibility and performance.
• The initial cost of implementing on automation system is very high.
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CHAPTER 6 : CONCLUSION
A small sum up of all those thing which were done by our company and our participation
in that work. Our company make a panel that is used for controlling the machine or other
appliances. Panel have their type which includes control panel, PLC panel, manual panel etc. Our
participation in this work with have some aim that we learn about the panel, panel making, panel
working and this internship give us the opportunity to fulfil all our aim. In internship period we
going through the panel we learnt about panel body, panel components, panel types, panel working,
panel uses.
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CHAPTER 7: REFERENCE
1. https://realpars.com/electrical-control-panel
2. https://www.electrical4u.com/programmable-logic-controllers
3. https://elecsafety.co.uk/electrical-control-panels
4. www.electricaltechnology.org
5. https://industlabs.com/news/electrical-control-panel-needs
6. https://www.automationreadypanels.com/electrical-components/electrical-
controlpanel/
7. https://www.expertengineers.co.in/blog/types-of-electrical-control-panel/
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